Tetrahedrite Thermoelectric Materials via High-Energy Milling
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Solution Overview
Problem
Current thermoelectric materials are often made from rare or toxic elements, requiring complex and costly synthesis procedures, which hinders their large-scale application due to environmental and economic concerns.
Innovation Solution
The development of thermoelectric devices using high-energy milled tetrahedrite materials formed from natural tetrahedrite ore and pure elements, specifically Cu12-xMxSb4S13 where M is Zn or Fe, which are earth-abundant and can be processed into a p-type material with high thermoelectric figure of merit through a simple powder processing method.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If traditional thermoelectric materials (Bi2Te3, PbTe) are used to achieve high ZT values, then thermoelectric performance is improved, but the materials become rare, toxic, and costly
Solution Approach 1:
The patent replaces expensive, rare, and toxic elements (Bi, Pb) with cheap, abundant, and non-toxic elements (Cu, Zn, Fe, Sb, S) to create thermoelectric materials that are environmentally friendly and economically viable for large-scale application while maintaining acceptable ZT values
Solution Approach 2:
The patent achieves high ZT values by precisely controlling compositional parameters (x in Cu12-xMxSb4S13), doping concentrations, and processing conditions (hot pressing temperature, time, pressure) to optimize the balance between electrical conductivity and thermal conductivity in the tetrahedrite structure
2Reliability
If complex synthesis procedures are used to achieve high ZT values, then thermoelectric performance is improved, but manufacturing complexity and cost increase
Solution Approach 1:
The patent uses high-energy ball milling to pre-alloy the powder mixture of Cu, Zn/Fe, Sb, and S elements before hot pressing, which simplifies the subsequent sintering process and eliminates the need for complex multi-step synthesis procedures while achieving homogeneous composition and high ZT values
Solution Approach 2:
The patent optimizes hot pressing parameters (temperature range 300-500°C, pressure, time) to achieve dense samples with high ZT values through a simple one-step sintering process following ball milling, avoiding complex multi-stage heat treatments
3Reliability
If complex synthesis procedures are used to achieve high ZT values, then thermoelectric performance is improved, but manufacturing cost increases
Solution Approach 1:
The patent uses inexpensive starting materials (Cu, Zn, Fe, Sb, S powders) and simple processing equipment (ball mill, hot press) to produce thermoelectric materials at low cost, making large-scale manufacturing economically viable compared to using rare and expensive elements
Solution Approach 2:
The high-energy ball milling step pre-mixes and pre-alloys all components uniformly, eliminating the need for expensive and time-consuming zone melting, floating zone, or molecular beam epitaxy equipment and procedures, thereby significantly reducing manufacturing cost
Applied Scientific Principles
This section explains which scientific principles are used to turn an abstract innovation direction into a practical engineering solution.
Function Achieved in This Case
This approach results in lightweight, low-cost thermoelectric devices with high conversion efficiency, maintaining high thermoelectric performance over a wide range of compositions and simplifying synthesis procedures, utilizing earth-abundant elements and reducing material costs.
Implementation Method 1
Thermoelectric materials may be used for direct conversion of heat to electricity
Implementation Method 2
high-energy ball milling of natural mineral tetrahedrite and pure elements to form a nearly single-phase tetrahedrite powder
Implementation Method 3
hot pressed high energy milled tetrahedrite
Data Source
AI summary
Thermoelectric materials based on tetrahedrite structures for thermoelectric devices and methods for producing thermoelectric materials and devices are disclosed. The thermoelectric device has a pair of conductors and a p-type thermoelectric material disposed between the conductors. The thermoelectric material is at least partially formed of a hot pressed high energy milled tetrahedrite formed of tetrahedrite ore and pure elements to form a tetrahedrite powder of Cu12-xMxSb4S13 disposed between the conductors, where M is at least one of Zn and Fe.